KR102274123B1 - Device and method for providing structural reinforcement and/or sound and vibration control within the cavities of hollow members of a vehicle body - Google Patents

Abstract

an insert comprising an injection-molded carrier (9) made of a heat-resistant thermoplastic composition, wherein at least one of the first side (10) and the second side (15) of the carrier (9) is composed of a heat-expandable resin composition ( 1) An assembly is provided for providing structural reinforcement and/or acoustic/vibration damping to a hollow member of an automobile having one or more receptacles (12) adapted to receive and retain it. The carrier 9 may comprise, on at least one of the first side 10 or the second side 15 , a plurality of openings 11 forming a grid or lattice, wherein the assembly comprises the carrier 9 in a hollow member. a mounting member 20 adapted to fasten to the inner wall of the

Description

DEVICE AND METHOD FOR PROVIDING STRUCTURAL REINFORCEMENT AND/OR SOUND AND VIBRATION CONTROL WITHIN THE CAVITIES OF HOLLOW MEMBERS OF A VEHICLE BODY

The present invention relates to devices useful for providing structural reinforcement and/or acoustic and vibration control within the cavity of hollow members, such as those present in automobiles and the like.

In recent years, the use of various polymer-based foams for reinforcing, reinforcing, sealing or acoustically deforming hollow members such as door assemblies, pillars, rocker panels, etc. There has been considerable and growing interest in Quite often, such polymer-based foams assist in controlling and inducing the expansion of the expandable resin used to make the foam, and are themselves carriers that can help achieve the desired structural and acoustic properties. carrier) is used in combination. However, such carriers typically have to be custom designed for specific end-use applications. In addition, the amount of expandable resin used is generally significant, which further adds to the manufacturing cost.

Accordingly, there is a need for a versatile, universal design that can be applied to a wide variety of applications and that achieves a desired level of performance with an intumescent resin in a cost-effective manner.

[Summary of the invention]

In one aspect, the present invention provides an assembly comprising an injection-molded carrier comprised of a heat resistant thermoplastic composition, wherein the carrier has a first side and a second side, wherein at least one of the first side or the second side is provided. has one or more receptacles adapted to receive and retain an insert comprised of a heat-expandable resin composition.

Another aspect of the present invention is an injection-molded carrier comprised of a heat resistant thermoplastic composition, having a first side and a second side, wherein a plurality of openings in at least one of the first side or the second side comprises a grid. an injection-molded carrier that forms a grid or lattice, and fastening the carrier to the inner wall of a hollow member and facing the inner wall with a first side or a second side of the carrier spaced apart from the inner wall An assembly comprising a mounting member adapted to retain the

The assembly of the present invention may include one or a combination of two or more of the following features. The heat-resistant thermoplastic composition may be composed of polyamide. The one or more receptacles may be openings extending through the carrier from the first side to the second side. The assembly may further include one or more mounting members extending from the carrier. The carrier may have a grid or lattice structure. The first side and the second side may each have a plurality of receptacles adapted to receive and retain an insert comprised of a heat-expandable resin composition. The one or more receptacles may include one or more deflectable prongs adapted to engage a groove on the insert surface to retain the insert in place within the receptacle. The carrier may have a plurality of openings extending between the first side and the second side, the openings in total constituting at least 50% of the surface area of each of the first side and the second side. At least some of the openings may function as receptacles adapted to receive and retain an insert comprised of a heat-expandable resin composition. The one or more receptacles may include an insert comprised of a heat-expandable resin composition. The heat-expandable resin composition can provide a structurally reinforced foam and/or a vibration/acoustic damping foam when activated by heating. One end of the insert may extend beyond a surface defined by a side of the carrier. The insert may be cylindrical in shape and may include a surface groove extending around the circumference of the insert. The end of the insert extending beyond the plane defined by the surface of the carrier may be rounded or tapered. At least one of the first side and the second side may each have a plurality of receptacles adapted to receive and retain an insert comprised of a heat-expandable resin composition. The openings in their entirety constitute at least 50% of the surface area of each of the first side and the second side. The openings may be separated by a wall portion having a thickness ranging from about 1 to about 5 mm. The openings may be separated by a wall portion extending between the first side and the second side.

In another aspect, the present invention comprises placing an insert in a receptacle contained in an injection-molded carrier comprised of a heat resistant thermoplastic, wherein the carrier has a first side and a second side, and wherein the insert is heat resistant. - comprising an intumescent resin composition, said receptacle adapted to receive and retain an insert. In one embodiment, the insert may be placed into the receptacle either manually or by a robot.

In another aspect, the present invention provides structural reinforcement, sealing, or sealing to a hollow member comprising placing an assembly according to the invention within the hollow member and heating the thermally expandable resin composition to a temperature effective to expand the thermally expandable resin composition. A method of providing at least one of vibration/acoustic damping is provided.

In another aspect, the present invention comprises an assembly within a hollow member (an injection-molded carrier comprised of a heat resistant thermoplastic, wherein the carrier has a first side and a second side, wherein either the first side or the second side is at least one having one or more receptacles containing an insert comprised of a heat-expandable resin composition, and heating the thermally expandable resin composition to a temperature effective to expand the thermally expandable resin composition. A method of providing at least one of reinforcement or vibration/acoustic damping is provided.

In another aspect, also provided by the present invention, there is an assembly comprising a hollow member, wherein therein is an assembly comprising an injection-molded carrier comprised of a heat resistant thermoplastic material, wherein the carrier comprises a first side and a second side, wherein at least one of the first side or the second side has one or more receptacles, wherein a portion of the expanded resin composition is positioned inside the receptacle, and a portion of the expanded resin composition extends from the receptacle and is hollow A structurally reinforced and/or vibration/acoustic damped hollow member that is in contact with an inner surface of the member, such as an inner wall.

An injection-molded carrier comprised of a heat resistant thermoplastic composition, the carrier having a first side and a second side, wherein a plurality of openings in at least one of the first side or the second side form a grid or lattice; and Also provided is an assembly comprising a mounting member adapted to fasten to the inner wall of the hollow member and retain the first or second side of the carrier spaced from the outer wall and facing the inner wall while being spaced apart from the inner wall.

Also provided by the present invention is a hollow member having an assembly according to the invention therein.

1 shows a top view of a representative insert according to one embodiment of the present invention.
2 is a cutaway view of a deflectable prong that may be positioned within a carrier receptacle in accordance with one aspect of the present invention.
3 is a detailed view of a portion of the combination of the insert of FIG. 1 and the deflectable prongs of FIG. 2 ;
4 shows a diagram of an exemplary carrier in accordance with one aspect of the present invention.
Fig. 5 shows an edge view of the carrier of Fig. 4 positioned with the hollow of the hollow member;
6 shows a diagram of an exemplary carrier according to another aspect of the present invention.
7 shows an edge view of the carrier shown in FIG. 6 .

The carrier part of the assembly is comprised of a heat resistant thermoplastic composition and may be formed by injection molding the thermoplastic composition. The carrier part generally has a first side and a second side opposite to each other. Once the assembly is positioned within the cavity of the hollow member, one or both of the first side and the second side may face the inner wall of the hollow member (eg the first side may face the first inner wall) and the second side may face the second inner wall). One or more receptacles are present on one or both of the first side and the second side. The receptacle is adapted to receive and retain the insert. In one embodiment, one of the first side or the second side comprises a plurality of such receptacles. In another embodiment, both the first side and the second side each comprise a plurality of receptacles. The carrier typically has a thickness between the first side and the second side. The thickness may be uniform such that the first side and the second side are generally parallel to each other, or it may be variable such that the first side and the second side are not parallel to each other. Generally, the carrier thickness is in the range of about 1 to about 10 cm. When viewed from the first side or the second side, the carrier may be of any desired shape, such as, for example, square, rectangular, hexagonal, trapezoidal, circular, oval, triangular, etc., or may be irregular in shape. In one embodiment, the carrier is cut and shaped to fit within the cavity of the hollow member within which it is positioned. For example, the carrier thickness may be such that at least one of the first side and the second side of the carrier is substantially parallel to an interior surface, such as an interior wall, of the hollow member it faces when the carrier is positioned within its cavity and is substantially parallel to the carrier side and the interior hollow. The distance between the member surfaces may be selected to be, for example, about 1 to about 5 cm. The surface defined by the first side or the second side may be of any suitable shape, such as flat (planar), curved (eg, concave, convex) or angled.

The carrier may be one-piece, a single integral part molded from a thermoplastic composition into a desired shape and configuration. However, in another embodiment, the carrier may comprise a plurality of carrier parts formed separately (eg by injection molding) and then joined together to provide a carrier for use in the assembly of the present invention. Such interlocking of the carrier parts may be accomplished by any suitable means, such as mechanical interlocking of the carrier parts, clips holding adjacent carrier parts together, adhesives, screws or the like. The individual carrier parts may be identical to or different from each other. Since different assembly end-use applications may have different requirements with respect to the size of the carrier part, standard carrier parts may be provided which may be joined together in different ways to provide carriers of different sizes and configurations. For example, if a standard carrier part has a first side and an opposing second side that are 10 cm x 10 cm square, the specific application requirements (such as the internal dimensions and shape of the hollow member to be structurally reinforced and/or damped) ), four such parts can be joined together to provide a carrier of 20 cm x 20 cm square or a carrier of 10 cm x 40 cm rectangle.

The thermoplastic composition used in the carrier body is selected and formulated so that it can be injection molded to provide a material that is relatively rigid and dimensionally thermally stable. Any of the heat resistant thermoplastics known in the art, including engineering thermoplastics, may be used as part of the thermoplastic composition. In one embodiment, the thermoplastic composition comprises a polyamide. Nylon 6.6 is an example of a suitable polyamide. The thermoplastic composition may include any of the additives known in the art including, for example, fillers (such as glass fibers), stabilizers, impact modifiers, colorants, processing aids, and the like. In one embodiment of the present invention, a thermoplastic composition is selected that provides a carrier capable of withstanding a temperature of at least 121° C. for at least 30 minutes without exhibiting any dimensional distortion.

One or both of the first side or the second side of the carrier may be characterized by the presence of one or more openings, more preferably a plurality of openings. In one embodiment of the present invention, at least one opening, preferably a plurality of openings, is configured to function as a receptacle (ie an opening adapted to receive and retain an insert comprised of a heat-expandable resin composition). However, in another embodiment, the carrier does not include any openings that can function as insert receptacles. Such an opening may penetrate entirely through the body of the carrier from the first side to the second side (forming a through hole), or it may be otherwise blocked or restrained at some point or points along its length. In one embodiment, the opening is configured to penetrate the carrier such that the carrier resembles an open grid or lattice (eg rectangular grid, honeycomb grid) when viewed from the first side or the second side. The opening may be of any suitable cross-sectional shape, such as square, rectangular, hexagonal, circular, triangular, trapezoidal, and the like. The openings may be the same or different from each other. In one aspect of the invention, the size and number of openings are such that the openings constitute at least 50%, at least 60%, or at least 70% of the surface area of one or both sides of the carrier. However, it will generally be desirable for the openings in their entirety to constitute no more than 90% or no more than 80% of the surface area of one or both sides of the carrier. Such an arrangement allows the carrier to be positioned within the cavity of the hollow member and without unduly compromising its stiffness or ability to contribute to the structural strengthening properties of the assembly after the thermally expandable resin composition of the insert(s) has been activated by heating. helps to reduce the weight and cost of The thickness of the wall portion separating the openings, as desired or necessary, determines the ability of the hollow member within which the carrier is to be positioned to withstand a load or force applied to the hollow member that would tend to destroy the hollow member in the absence of the carrier. can be modified to meet the relevant requirements. The wall thickness may be, for example, about 1 to 5 mm.

The carrier of the present invention also comprises one or more receptacles, advantageously adapted to receive and retain an insert composed of a heat-expandable resin composition on its first side or on its second side, or on both the first and second side thereof, advantageously It is characterized in that it comprises a plurality of receptacles. The aforementioned opening may be adapted to function as such a receptacle. All or only some of the openings may be adapted as such.

Any suitable means for holding the insert in place within the receptacle may be used. Advantageously, the insert is subjected to the handling normally encountered when the receptacle and the carrier containing the insert are held face down, or when the assembly is manufactured, stored, transported and then installed into a hollow member of an automobile or the like. When applied, the insert is retained sufficiently to prevent it from falling out of the receptacle. Retention of the insert can be achieved, for example, by precisely dimensioning the insert and the receptacle to achieve a press fit between the parts in question, in which case the insert is held by the frictional force between the insert surface and the inner surface of the receptacle. . To bond the insert to the inner surface of the receptacle, an adhesive may be used. In one embodiment, the heat-expandable resin composition used to make the insert is selected to have hot melt adhesive or pressure sensitive adhesive characteristics such that the insert itself has adhesive properties that are essentially capable of retaining the insert in the receptacle and can be combined. In one advantageous embodiment of the invention, the receptacle comprises at least one deflectable prong adapted to engage a groove on the insert surface to retain the insert in place within the receptacle. Where a receptacle has more than one deflectable prong, the prongs may be spaced evenly around the interior perimeter of the receptacle. For example, if a receptacle has two deflectable prongs, such prongs may be positioned opposite each other. A deflectable prong (without the application of an external force) allows the prong to be deflected from its original position by application of a force perpendicular to the longitudinal axis of the prong and return to its original initial position (without application of an external force) once that force is removed. ) may be composed of a resilient material. In one embodiment, the deflectable prongs are made of the same heat resistant thermoplastic as the carrier (such as glass-filled polyamide or other engineering thermoplastic).

To facilitate the manufacture of an assembly according to the present invention, all receptacles present in the carrier may be uniform in size and shape, and may receive and retain one particular type of insert. However, also contemplated by the present invention is a carrier having two or more different types of receptacles adapted to receive and retain two or more different types of inserts.

The aforementioned carrier receptacle is configured to receive and retain an insert comprised of a heat-expandable resin composition. Where the assembly comprises a plurality of such inserts, the inserts may be made from the same heat-expandable resin composition, or from different heat-expandable resin compositions having varying properties and characteristics. Inserts used in individual assemblies may also have different sizes, shapes, and the like. However, for ease of manufacture, in one embodiment, the plurality of inserts used to make the assembly are the same.

To simplify insertion of the insert into the receptacle, each insert may be symmetrical in cross-section so that the insert does not need to be oriented in one particular way to achieve such insertion. Specifically, the insert preferably has a circular cross-sectional shape. Generally speaking, the cross-sectional shape of the insert exactly matches the cross-sectional shape of the receptacle so that the insert fits comfortably within the receptacle. It is also generally advantageous for the insert to be substantially uniform in cross-section over most of its length, as such an arrangement also helps to facilitate insertion of the insert within the receptacle. For example, in one embodiment, the insert is cylindrical in shape. However, the end of the insert may have a smaller cross-section relative to the main or central body of the insert, which helps guide the insert into the receptacle when it is inserted. For example, one or both ends of the insert may be tapered or rounded. As previously mentioned, the outer surface of the insert may include a groove arranged within the receptacle and adapted to receive a deflectable prong capable of holding the insert in place within the receptacle. The groove may extend around the entire perimeter of the insert surface, or alternatively may extend around less than the entire perimeter. In one embodiment of the invention, such a groove is located approximately mid-point of the length of the insert. If the insert is symmetrical about its center point, positioning the groove at the mid-point of the insert will lead to the final arrangement of the insert when inserted and held in the receptacle is independent of which end of the insert is inserted into the receptacle. . The manufacture of the inventive assembly can thereby be made simpler.

The overall length of the insert can be adjusted and adjusted, if desired, to suit a specific end-use application. In one embodiment, once inserted and held in the receptacle of the carrier, one end of the insert extends beyond the surface defined by the first or second side of the carrier. However, in other embodiments, the end may be flush with or even below the surface. The length of the insert is such that once the insert is positioned in the receptacle and the product assembly is positioned as desired within the hollow member, the end of the insert that extends furthest from the surface defined by the side of the carrier is the inner surface of the hollow member (such as the side of the carrier). may be selected to be within a distance of 1 to 5 mm from the facing inner surface).

The insert used in the assembly of the present invention is comprised of a heat-expandable resin composition. Heat-expandable resin compositions are well known in the art, typically one or more polymers and/or polymer precursors, as well as one or more heat-activated blowing agents that cause the composition to expand (foam) when the composition is heated. contains To be precise, the heat-activated blowing agent is a latent blowing agent in that it is stable at room temperature and only activates when the composition is heated to or above a certain temperature (sometimes referred to as the activation temperature) and functions as a volatile expanding agent. In one embodiment of the invention, the blowing agent is selected to have an activation temperature above the temperature at which the heat-expandable resin composition can be shaped into an insert (eg, by injection molding or extrusion). After the heat-expandable resin composition is activated by heating an assembly comprising one or more inserts composed of the heat-expandable resin composition is placed in the hollow member and the resin composition is heated to expand, it provides the hollow member with structural reinforcing properties, acoustic / It can be formulated to impart vibration damping properties, or both structural strengthening and acoustic/vibration damping properties.

The heat-expandable resin composition used in the inserts of the present invention contains at least one polymer and/or polymer precursor, and at least one latent blowing agent, which is sufficient at ambient temperature to allow structures made therefrom to be self-supporting. It may be selected from any of the materials known in the art having dimensional stability. In one embodiment, the resin composition (or at least its outer surface) is substantially non-tacky at ambient temperature and yet capable of softening or melting at elevated temperatures, such that the desired configuration is achieved by injection molding or the like without activating the latent blowing agent(s). may be shaped or formed into In one embodiment of the present invention, the resin composition is elastic. The latent blowing agent is subjected to external heating (such as a temperature in the range of about 120° C. to about 220° C., which is the temperature range typically encountered by automotive bodies when baking a finish coating on the body) for about 10 minutes to about 150 minutes. can be selected to provide properties of foaming and expanding the resin composition. The polymer may be a thermoplastic polymer, a rubber (elastomer including a crosslinkable or curable elastomer) and/or a thermoplastic elastomer. Suitable thermoplastic polymers include, for example, ethylene-vinyl acetate copolymers, copolymers of ethylene and alkyl (meth)acrylates, polyethylene, polypropylene and polyesters. Suitable rubbers and thermoplastic elastomers include, for example, styrene-butadiene rubber (SBR), ethylene-propylene rubber, ethylene-propylene-diene monomer rubber (EPDM), polybutadiene, styrene-isoprene-styrene block copolymer, styrene-butadiene-styrene block copolymers, styrene-ethylene/butylene-styrene block copolymers, styrene-ethylene/propylene block copolymers, nitrile rubbers, chlorinated polyethylene rubbers, and the like. Materials or substances, including polymer precursors, prepolymers, resins, etc., which are monomeric or oligomeric in their nature to be cured, crosslinked and/or chain extended upon heating, may also be used by themselves as well as in combination with one or more polymers. have. Examples of suitable polymer precursors include, but are not limited to, epoxy resins, polyurethane prepolymers, and the like. Accordingly, the resin composition may be thermoplastic, thermoset, or, in one particularly preferred embodiment, both thermoplastic and thermoset (i.e. may be shaped or molded at appropriate elevated temperatures, as well as cured or crosslinked at higher temperatures).

The latent blowing agent or blowing agents present in the polymer matrix cause swelling or foaming of the resin composition when heated to an elevated temperature. Latent blowing agents are, for example, “chemical blowing agents” and/or “physical blowing agents” that release gases by decomposition on heating, i.e. expandable hollow beads (also referred to as expandable microspheres) that expand in volume when heated. It may be any blowing agent known in the art. Combinations of different blowing agents may be used, for example, a blowing agent having a lower activation temperature (eg about 100° C.) may be used with a blowing agent having a higher activation temperature (eg about 180° C.). The amount of latent blowing agent is selected to provide the desired volumetric expansion of the resin composition when heated to a temperature effective to activate the blowing agent. The amount of latent blowing agent typically ranges from about 5, 6, 7, 8, 9, 10, 11, or 12 weight percent to about 15, 16, 17, 18, 19 or 20 weight percent of the total resin composition.

Depending on the amount and type(s) of the blowing agent(s) used in the resin composition, as well as other factors (eg, the presence of the foaming accelerator/activator, the nature of the polymer(s)/polymer precursor(s)), the polymer matrix is at least about 50%, or at least about 100%, or at least about 250%, or at least about 500%, or at least 750%, or at least 1000% in volume relative to the initial volume of the heat-expandable resin composition when heated. can be combined.

In addition, additives known in the art, such as, for example, a crosslinking agent, a curing agent, and the like, may be added to the resin composition to promote curing and/or crosslinking of the polymer or polymer precursor. Such crosslinkers and curing agents are selected based on the type(s) of the polymer or polymer precursor used in the polymer matrix. In a preferred embodiment of the present invention, the crosslinking agent(s) and/or curing agent(s) are latent, ie stable/non-reactive at ambient temperature, but are activated when the polymer matrix is heated to an elevated temperature. In such embodiments, the polymer matrix expands and crosslinks/curs as a result of such heating. The type of crosslinking agent(s)/curing agent(s) used is generally selected to be compatible with the other components of the heat-expandable resin composition, in particular the polymer(s) and polymer precursor(s).

Additives known in the art such as, for example, impact modifiers, stabilizers, reinforcing agents, fillers, emollients, plasticizers, waxes, antioxidants, pigments, colorants, fungicides, tackifiers, waxes and/or flame retardants may also be thermal- may be present in the expandable resin composition.

For example, resins sold under the trade names TEROCORE (used primarily for structural reinforcement) and TEROPHON (used primarily for acoustic and vibration damping) by Henkel Corporation and its affiliates Heat-expandable resin compositions suitable for use in the present invention, including those, are commercially available.

The insert may be formed into its desired shape and configuration by any suitable means, such as injection molding.

The assembly of the present invention may further include one or more mounting members. Such a mounting member may be adapted to hold the assembly in a desired position within the hollow member by fastening the assembly to the inner surface of the hollow member. The mounting member may, for example, be integral with the carrier or otherwise manufactured separately and coupled to the carrier via adhesive or mechanical means (eg clips, rivets, bolts, screws) or the like. For example, the mounting member(s) and the carrier may be integrally formed by injection molding the heat resistant thermoplastic composition. The mounting member may protrude away from the carrier main body in a manner such that the main body of the carrier (including the insert) is maintained in a desired direction from, and a desired spacing from, the inner surface of the hollow member. For example, in one embodiment, the mounting member extends outwardly from the first and/or second side of the carrier. In another embodiment, the mounting member extends outwardly from an edge of the carrier. The mounting member includes means for securing the assembly to the hollow member. Such means are well known in the art and include, for example, clips, so-called "Christmas tree" fasteners and the like. Such clips or fasteners are insertable through an opening in the hollow member and have an engagement projection that engages an outer periphery of the hollow member proximate to the opening to hold the assembly in place by preventing withdrawal of the engagement projection from the opening. can

To aid in positioning the assembly in a desired manner within the hollow member, the assembly may include one or more spacer members that protrude from the sides or edges of the carrier, such as mounting members. The spacer member has a length effective to maintain a minimum desired spacing between the hollow member inner wall and the carrier main body. However, the spacing member lacks means for fastening or physically coupling the assembly to its interior wall. Like the mounting member, the spacing member may be integrally formed with the carrier, or may be separately coupled to the carrier.

The carrier and insert are manufactured separately, and then the insert is placed in the desired receptacle of the carrier to the extent necessary to allow the insert to be held in the receptacle, thereby allowing the assembly to be handled and transported without detaching the insert from the carrier. can be combined to form an assembly according to the present invention. For example, if the receptacle includes one or more deflectable prongs adapted to engage a groove on the surface of the insert, the insert is inserted into the receptacle to the extent necessary for such engagement to occur. Insertion of the insert may be performed manually (ie, by an operator) or by a robot, wherein the robot is programmed to insert the plurality of inserts into the plurality of carrier receptacles to provide a desired insert pattern on one or both sides of the carrier. can be

An assembly consisting of a carrier and one or more inserts may then be positioned within a hollow member requiring or desirable for structural reinforcement and/or acoustic/vibration damping, wherein the assembly may then be positioned within a hollow member using one or more of the aforementioned mounting members. One or more of them are fixed to the inner wall. The hollow member may be, for example, a vehicle component such as a pillar, a rocker panel, a door assembly, a channel, a rail, and the like. Typically, the hollow member is made of a metal such as sheet metal. The assembly is then subjected to heating (eg, a temperature of from about 120° C. to about 210° C.) for an amount of time sufficient to allow the heat-expandable resin composition present in the insert(s) to expand (foam). Upon cooling, a polymeric foam matrix is obtained which imparts the desired structural strengthening and/or acoustic/vibration damping properties to the hollow member. Generally speaking, the assembly is selected and designed so that upon activation, the heat-expandable resin composition expands sufficiently in volume so that it connects between the carrier and the hollow member inner wall surface. In some embodiments, the polymeric foam matrix is adhered (attached) to the interior wall surface. Where the side of the carrier comprises a plurality of receptacles and a plurality of inserts, the polymeric foam matrix produced by expansion of the individual inserts may be maintained separately from the polymeric foam matrix or matrices produced from each of the other inserts. However, in other embodiments, after the insert is aligned, the volume expands sufficiently once the heat-expandable resin composition used in the insert is activated, such that the polymeric foam matrices produced by two or more adjacent inserts can be fused to each other. have. In one embodiment, the polymeric foam matrix/matrices and carrier can cooperate to provide a full barrier seal of the hollow member.

1 shows an exemplary insert in accordance with one aspect of the present invention. Insert 1 is generally cylindrical in shape with a circular cross-section and rounded ends 3A and 3B. At approximately mid-point of the length of the insert 1 , there is a groove 2 , in which case the groove 2 is present on the surface of the insert 1 and extends around the circumference of the insert 1 . The groove 2 has a lip 8 .

2 shows a deflectable prong 4 positioned within a receptacle (not shown) of a carrier according to an embodiment of the present invention, wherein the deflectable prong 4 engages the groove 2 of the insert 1 . It is adapted to hold the insert 1 in place in the receptacle. The deflectable prong (4) has a notch (5). For example, a receptacle may generally include two such deflectable prongs arranged facing each other on opposite sides of the interior of the receptacle.

3 shows how the deflectable prongs 4 and the grooves 2 of the insert 1 can interact to hold the insert 1 in place in a receptacle (not shown) of a carrier according to an embodiment of the present invention. show whether The insert 1 is inserted into the receptacle in the direction indicated by the arrow, with the rounded end 3B being the first part of the insert 1 introduced into the receptacle. When the insert is inserted, one end of the deflectable prong 4 is directed away from the insert 1 as the tip 7 of the deflectable prong 4 slides along the outer surface 6 of the insert 1 . is biased towards Once the tip 7 has reached the groove 2 , the end of the deflectable prong 4 made of resilient material is deflected towards the insert 1 , whereby the tip 7 enters the groove 2 . The notch 5 interacts with, ie engages with, the lip 8 . As a result, the insert 1 is held in place in the receptacle so that it cannot be easily inserted further into the receptacle or withdrawn from the receptacle.

4 shows a carrier 9 according to an embodiment of the invention. In this figure, a representative carrier is shown as a top view of a first side 10 comprising both a plurality of openings 11 and receptacles 12 . The receptacle can be coupled with the insert 1 shown in FIG. 1, for example, through the use of a deflectable prong, such as the deflectable prong 4 shown in FIG. 2 (corresponding prong not shown in FIG. 4) positioned within the receptacle. adapted to receive and retain the same cylindrical insert. In the final assembly, inserts need not be present in all receptacles of the carrier. Rather, it depends on the particular end-use application desired (eg, the type of hollow member to be reinforced and/or damped using the assembly, the degree of reinforcement/damping required for the hollow member comprising the assembly to meet certain pre-selected criteria). As a guide, the number of receptacles containing inserts and the pattern of such insert-containing receptacles on one or both sides of the carrier may vary. The opening 11 lacks said deflectable prongs and, in the embodiment shown in FIG. 4 , is generally rectangular in shape. In the embodiment shown as such, both the opening 11 and the receptacle 12 extend through the carrier 9 from the first side 10 to the second side, so that the second side is substantially the same as the first side. mirror image. The plurality of openings 11 forms a generally open grid or lattice, thereby helping to reduce the weight of the carrier 9 while still providing adequate strength and rigidity. The openings 11 are separated by a wall 26 having a thickness of, for example, 1 to 5 mm.

FIG. 5 shows an edge view of the carrier 9 shown in FIG. 4 , with the insert 1 positioned in the receptacle 12 . The first side 10 of the carrier faces towards the inner wall 13 of the panel 14 and the second side 15 of the carrier 9 faces towards the inner wall 16 of the panel 17 . . The first side 10 and the second side 15 are spaced apart by a thickness “t”. Panel 14 and panel 17 together define hollow 18 of hollow member 19 . Panels 14 and 17 may be made of, for example, sheet metal or the like, and one panel, for example panel 17, may be an outer panel. The carrier 9 is fastened to the inner wall 13 of the panel 14 using a mounting member 20 so that a portion of the mounting member 20 can extend through the opening 23 of the panel 14 . It has a resilient engagement protrusion 21 that can be biased towards a stem 22 so as to The engaging projection 21, once passed through the opening 23, returns to its original position and engages the outer surface 24 of the panel 14, thereby preventing withdrawal of the mounting member 20 from the opening 23. restrain The base 25 of the mounting member 20 is wider relative to the opening 23 , so that it engages the inner surface, ie the inner wall 13 of the panel 14 , to further hold the assembly fixed in place. (ie the assembly is coupled or fastened to the panel 14). When the resin composition present in each insert 1 is activated by heating, the insert 1 will generally form a final expanded polymer matrix or matrices from each side 10 and 15 of the carrier 9 to the inner wall. It extends in a direction towards the inner walls 13 and 16, so as to extend to (13) and (16). The presence of the expanded polymer matrix/matrices in the space between the carrier 9 and the interior walls 13 and 16 depends on the composition and characteristics of the heat-expandable resin composition selected for use in the insert 1 , the hollow member It serves to structurally strengthen (19) and/or damp the hollow member (19) against acoustics and vibrations.

6 shows a carrier 9 according to another embodiment of the invention. In this figure, a representative carrier is shown as a top view of a first side 10 comprising a plurality of rectangular openings 11 . A mounting member 20 having an engaging projection 21 and a base 25 is shown positioned on the carrier 9 . Optionally, one or more of the openings 11 may be adapted to function as a receptacle capable of receiving and retaining an insert comprised of a heat-expandable resin composition. Alternatively, the opening 11 may have a non-rectangular shape such as triangular, square, hexagonal or circular. It is not necessary that the openings 11 are all the same size or shape. In the embodiment so shown, the opening 11 extends through the carrier 9 from the first side to the second side, so that the second side is in fact a mirror image of the first side. The plurality of openings 11 forms a generally open grid or lattice, thereby helping to reduce the weight of the carrier 9 while still providing adequate strength and rigidity. The openings 11 are arranged between the openings 11 and are separated by a wall 26 having a thickness of, for example, 1 to 5 mm.

7 shows an edge view of the carrier 9 shown in FIG. 6 . The first side 10 of the carrier faces the inner wall 13 of the panel 14 and the second side 15 of the carrier 9 faces the inner wall 16 of the panel 17 , (17) is the outer panel. The first side 10 and the second side 15 are spaced apart by a thickness “t” (in other words, the length of the wall portion 26 separating the openings 11 is equal to the thickness “t” of the carrier 9 ). applicable). Panel 14 and panel 17 together define hollow 18 of hollow member 19 . The carrier 9 is fastened to the inner wall 13 of the panel 14 using a mounting member 20 so that a portion of the mounting member 20 can extend through the opening 23 of the panel 14 . It has a resilient engagement protrusion 21 that can be biased towards the stem 22 so as to The engaging projection 21, once passed through the opening 23, returns to its original position and engages the outer surface 24 of the panel 14, thereby preventing withdrawal of the mounting member 20 from the opening 23. restrain The base 25 is wider than the opening 23 so that it further engages an interior surface, ie, the interior wall 13 of the panel 14, to hold the assembly securely in place (ie, the assembly is secured to the panel 14). coupled or fastened to). The spacing member 27 protrudes from the side 10 of the carrier 9 and has a length effective to hold the side 10 away from the inner surface 13 at a minimum distance. The presence of the carrier 9 between the inner walls 13 and 16 serves to structurally strengthen the hollow member 19 . In other words, as a result of the presence of the carrier 9 within the hollow member cavity, the hollow member 19 has increased resistance to crushing due to application of a force or load generally normal to the panel 14 or 17 . show tolerance. As FIG. 7 shows, the carrier 9 is not in physical contact with the panel 17 . However, due to its grid or lattice structure, and the relatively low density of the thermoplastic resin composition used to make the carrier, the assembly does not substantially contribute to the weight of the hollow member. Thus, the hollow member is structurally in a cost effective manner while maintaining a light weight compared to other known approaches for improving the crush resistance of the hollow member (such as increasing the thickness of the metal used to make the hollow member). can be strengthened with

Although features of the invention may have been described in the context of only one of the illustrated embodiments, such features may be combined with one or more other features of other embodiments for any given use.

In view of the above, it will also be appreciated that the production of the assemblies disclosed herein and their use also constitute a method according to the present invention. Unless otherwise stated, the dimensions and shapes of the various assemblies and components thereof described and shown herein are not intended to limit the invention, and other dimensions or configurations are possible.

Preferred embodiments of the present invention have been disclosed. Those of ordinary skill in the art will recognize that certain modifications also fall within the teachings of the present invention. Accordingly, the following claims determine the scope and content of the present invention.

Claims (22)

An injection-molded carrier comprised of a heat resistant thermoplastic composition, wherein the carrier has a first side and a second side, wherein at least one of the first side or the second side receives an insert comprised of a heat-expandable resin composition; An assembly having one or more receptacles adapted to retain, wherein the one or more receptacles contain one or more deflectable prongs adapted to engage a surface of the insert and retain the insert in place within the receptacle. The assembly of claim 1 , wherein the one or more receptacles are openings extending through the carrier from the first side to the second side. The assembly of claim 1 , further comprising one or more mounting members extending from the carrier. The assembly of claim 1 , wherein the carrier has a grid or lattice structure. The assembly of claim 1 , wherein both the first side and the second side have a plurality of receptacles each adapted to receive and retain an insert comprised of a heat-expandable resin composition. The assembly of claim 1 , wherein the insert comprises a groove on a surface of the insert, and wherein the one or more deflectable prongs are adapted to engage the groove and retain the insert in place within the receptacle. The carrier of claim 1 , wherein the carrier has a plurality of openings extending between the first side and the second side, the openings in total constituting at least 50% of the surface area of each of the first side and the second side. assembly. The assembly of claim 2 , wherein at least some of the openings can function as a receptacle adapted to receive and retain an insert comprised of a heat-expandable resin composition. The assembly of claim 1 , wherein the at least one receptacle contains an insert comprised of a heat-expandable resin composition, the insert providing at least one of a structurally reinforcing foam and a vibration/acoustic damping foam when activated by heating. 10. The assembly of claim 9, wherein one end of the insert extends beyond a surface defined by at least one of the first side or the second side of the carrier. 11. The assembly of claim 9 or 10, wherein the insert is cylindrical in shape and has a surface groove extending at least partially around a circumference of the insert. 11. The assembly of claim 9 or 10, wherein one end of the insert extending beyond a surface defined by at least one of the first side or the second side of the carrier is rounded or tapered. and placing the insert in a receptacle contained in an injection-molded carrier comprised of a heat resistant thermoplastic, wherein the carrier has a first side and a second side, the insert is comprised of a heat-expandable resin composition, and the receptacle comprises: wherein the receptacle contains one or more deflectable prongs adapted to receive and retain an insert and to engage a surface of the insert to retain the insert in place in the receptacle. The assembly according to any one of claims 1 to 10 is placed in a hollow member and activated by heating the thermally expansible resin composition in the assembly to expand, whereby a portion of the expanded resin composition contacts the inner surface of the hollow member. A method of providing at least one of structural reinforcement, sealing or vibration/acoustic damping to a hollow member, comprising: A hollow member having an assembly according to any one of claims 1 to 10 therein. 11. An assembly according to any one of the preceding claims, for providing the hollow member with one or more of structural reinforcement, sealing or vibration/acoustic damping. There is an assembly comprising a hollow member and within the hollow member is an assembly comprising an injection-molded carrier comprised of a heat resistant thermoplastic, wherein the carrier has a first side and a second side, wherein the first side or the second side at least one of the receptacles has one or more receptacles extending from the first side to the second side through the carrier, a portion of the expanded resin composition positioned within the receptacle, the portion of the expanded resin composition extending from the receptacle and being hollow A hollow member provided with at least one of structural reinforcement and vibration/acoustic damping, wherein the hollow member is in contact with an inner surface of the member. An injection-molded carrier comprised of a heat resistant thermoplastic composition, having a first side and a second side, wherein a plurality of openings in at least one of the first side or the second side form a grid or lattice, the first side or the second side At least one of the two sides has one or more receptacles adapted to receive and retain an insert comprised of a heat-expandable resin composition, the one or more receptacles adapted to engage a surface of the insert to retain the insert in place within the receptacle. contain one or more deflectable prongs, the openings in their entirety constituting at least 50% of the respective surface area of the first side and the second side, at least some of the openings extending from the first side to the second side through the carrier an extended carrier, and
a mounting member adapted to fasten the carrier to the inner wall of the hollow member and retain the first or second side of the carrier spaced apart from the outer wall and facing the inner wall while being spaced apart from the inner wall
assembly comprising a. 19. The assembly of claim 18, wherein the heat resistant thermoplastic composition consists of polyamide. The assembly of claim 18 , wherein the openings are separated by wall portions extending between the first side and the second side, the wall portions having a thickness of from 1 to 5 mm. 21. Positioning the assembly according to any one of claims 18 to 20 in a hollow member, and activating by heating a thermally expandable resin composition in the assembly to expand, whereby a portion of the expanded resin composition contacts the inner surface of the hollow member. A method of providing structural reinforcement to a hollow member, comprising: delete

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